Aerosol Delivery Device Comprising Multiple Outer Bodies and Related Assembly Method

ABSTRACT

The present disclosure relates to an aerosol delivery device. The aerosol delivery device may include a first outer body, a second outer body, and a coupler received therebetween. A securing mechanism may couple the outer bodies together to retain the aerosol delivery device in an assembled configuration. Related assembly methods are also provided.

FIELD OF THE DISCLOSURE

The present disclosure relates to aerosol delivery devices such assmoking articles, and more particularly, to aerosol delivery devicesthat include multiple outer bodies. The aerosol delivery deviceincorporates an aerosol formation device or an atomizer. A typicalatomizer is configured to heat an aerosol precursor including componentsthat may be made or derived from tobacco or otherwise incorporatetobacco using an electrically powered resistance heater. As a result,the aerosol delivery device provides an inhalable substance for humanconsumption.

BACKGROUND

Many smoking devices have been proposed through the years asimprovements upon, or alternatives to, smoking products that requirecombusting tobacco for use. Many of those devices purportedly have beendesigned to provide the sensations associated with cigarette, cigar, orpipe smoking, but without delivering considerable quantities ofincomplete combustion and pyrolysis products that result from theburning of tobacco. To this end, there have been proposed numeroussmoking products, flavor generators, and medicinal inhalers that utilizeelectrical energy to vaporize or heat a volatile material, or attempt toprovide the sensations of cigarette, cigar, or pipe smoking withoutburning tobacco to a significant degree. See, for example, the variousalternative smoking articles, aerosol delivery devices and heatgenerating sources set forth in the background art described in U.S.Pat. No. 7,726,320 to Robinson et al., U.S. Pat. Pub. No. 2013/0255702to Griffith Jr. et al., U.S. Pat. Pub. No. 2014/0000638 to Sebastian etal., U.S. patent application Ser. No. 13/602,871 to Collett et al.,filed Sep. 4, 2012, U.S. patent application Ser. No. 13/647,000 to Searset al., filed Oct. 8, 2012, U.S. patent application Ser. No. 13/826,929to Ampolini et al., filed Mar. 14, 2013, and U.S. patent applicationSer. No. 14/011,992 to Davis et al., filed Aug. 28, 2013, which areincorporated herein by reference in their entirety.

Certain existing embodiments of aerosol delivery devices include asingle, unitary, elongated outer housing that is substantially tubularin shape. In these embodiments, all of the components of the aerosoldelivery device are at least partially contained within the single outerhousing. However, it would be desirable to provide an alternate form orconfiguration of an aerosol delivery device that enhances userexperience or allows for alternative manufacturing techniques. Thus,advances with respect to configurations of aerosol delivery devices andmethods of assembly thereof may be desirable.

BRIEF SUMMARY OF THE DISCLOSURE

The present disclosure relates to aerosol delivery devices configured toproduce aerosol. Certain types of these devices can be characterized aselectronic cigarettes. In one aspect an aerosol delivery device isprovided. The aerosol delivery device may include a first outer bodydefining an inlet aperture, a second outer body, a power sourcepositioned in the first outer body, an atomizer positioned in the secondouter body, and a coupler positioned between, and engaged with, thefirst outer body and the second outer body. The coupler may define acoupler inlet and a longitudinal channel. The coupler may be configuredto receive air from the inlet aperture defined in the first outer bodythrough the coupler inlet and to direct the air through the longitudinalchannel to the second outer body.

In some embodiments the aerosol delivery device may further include atleast one securing mechanism configured to substantially irreversiblysecure the first outer body to the second outer body. The at least onesecuring mechanism may be a wrapper extending at least partially aroundthe first outer body, the second outer body, and the coupler. Theaerosol delivery device may additionally include a reservoir substrateand a flow director positioned in the second outer body, the flowdirector may extend at least partially through the reservoir substrate.The flow director may define a transverse aperture extendingtherethrough, and the atomizer may extend through the transverseaperture.

In some embodiments a plurality of electrical connectors may extend fromthe atomizer through the coupler to the power source. The atomizer mayinclude a heating element and a liquid transport element defining acenter portion and first and second opposing arms extending therefrom,the heating element may be coupled to the center portion of the liquidtransport element. The coupler may define a nipple and the flow directormay engage the nipple of the coupler. Accordingly, the positioning ofthe components is such that an airflow passageway is created.

In some embodiments the aerosol delivery device may additional include amouthpiece defining a nipple, and the flow director may engage thenipple of the mouthpiece. The coupler may define a rib, and the rib mayseparate the first outer body from the second outer body. One of thefirst outer body and the second outer body may define an inlet aperturealigned with a recessed portion of the coupler.

In an additional aspect, a method for assembling an aerosol deliverydevice is provided. The method may include positioning a power source ina first outer body defining an inlet aperture, positioning an atomizerin a second outer body, and engaging a coupler defining a coupler inletand a longitudinal channel with the first outer body and the secondouter body such that the coupler is positioned to receive air from theinlet aperture defined in the first outer body through the coupler inletand to direct the air through the longitudinal channel to the secondouter body.

In some embodiments, the method may further include substantiallyirreversibly securing the first outer body to the second outer body witha securing mechanism. Substantially irreversibly securing the firstouter body to the second outer body with the securing mechanism mayinclude wrapping a wrapper at least partially around the first outerbody, the second outer body, and the coupler. The method mayadditionally include positioning a reservoir substrate and a flowdirector in the second outer body such that the flow director extends atleast partially through the reservoir substrate. Positioning theatomizer in the second outer body may include inserting the atomizerthrough a transverse aperture extending through the flow director.

In some embodiments the method may additionally include inserting aplurality of electrical connectors through the coupler and connectingthe electrical connectors to the power source and the atomizer.Additionally, the method may include coupling a heating element to acenter portion of a liquid transport element to form the atomizer andfolding first and second opposing arms of the liquid transport elementextending from the center section away from the coupler. Further, themethod may include coupling the flow director to a nipple of thecoupler. The method may also include coupling the flow director to anipple of a mouthpiece. Engaging the coupler with the first outer bodyand the second outer body may include engaging a rib of the coupler withthe first outer body and the second outer body. Engaging the couplerwith the first outer body may include aligning an inlet aperture definedthrough the first outer body with a recessed portion of the coupler.

In an additional embodiment a coupler for an aerosol delivery device isprovided. The coupler may include a first engagement portion configuredto engage a first outer body, a second engagement portion configured toengage a second outer body, a coupler inlet defined through a peripheralsurface of the first engagement portion, and a longitudinal channel influid communication with the coupler inlet and extending through thesecond engagement portion to a coupler outlet opening.

In some embodiments the coupler may additionally include a pressure portopening in fluid communication with at least one of the coupler inletand the longitudinal channel and extending through the first engagementportion. The coupler inlet may be defined between first and secondgrooves configured to respectively receive a gasket). Further, thecoupler may include a recessed portion at the peripheral surface of thefirst engagement portion, and the coupler inlet may be defined throughthe recessed portion. Additionally, the coupler may include a nippleconfigured to engage a flow director, and the longitudinal channel mayextend through the nipple.

These and other features, aspects, and advantages of the disclosure willbe apparent from a reading of the following detailed descriptiontogether with the accompanying drawings, which are briefly describedbelow. The invention includes any combination of two, three, four, ormore of the above-noted embodiments as well as combinations of any two,three, four, or more features or elements set forth in this disclosure,regardless of whether such features or elements are expressly combinedin a specific embodiment description herein. This disclosure is intendedto be read holistically such that any separable features or elements ofthe disclosed invention, in any of its various aspects and embodiments,should be viewed as intended to be combinable unless the context clearlydictates otherwise.

BRIEF DESCRIPTION OF THE FIGURES

Having thus described the disclosure in the foregoing general terms,reference will now be made to the accompanying drawings, which are notnecessarily drawn to scale, and wherein:

FIG. 1 illustrates a side view of an aerosol delivery device in anassembled configuration, the aerosol delivery device having the generalconfiguration of what can be characterized as an electronic cigarette,and comprising a first outer body, a second outer body, and a couplerpositioned therebetween according to an example embodiment of thepresent disclosure;

FIG. 2 illustrates a partially exploded side view of the aerosoldelivery device of FIG. 1 according to an example embodiment of thepresent disclosure;

FIG. 3 illustrates a side view of the aerosol delivery device of FIG. 1in an assembled configuration, wherein the aerosol delivery devicefurther comprises a wrapper according to an example embodiment of thepresent disclosure;

FIG. 4 illustrates an exploded perspective view of the aerosol deliverydevice of FIG. 1 according to an example embodiment of the presentdisclosure;

FIG. 5 illustrates a modified sectional view through the aerosoldelivery device of FIG. 1 at the first outer body and the coupleraccording to an example embodiment of the present disclosure;

FIG. 6 illustrates a sectional view through the coupler of FIG. 1 alongline A-A from FIG. 5 according to an example embodiment of the presentdisclosure;

FIG. 7 illustrates a bottom view of an atomizer, a flow director, amouthpiece, and the coupler of the aerosol delivery device of FIG. 1according to an example embodiment of the present disclosure;

FIG. 8 illustrates a side view of the flow director of FIG. 7 accordingto an example embodiment of the present disclosure;

FIG. 9 illustrates an end view of the flow director and the atomizer ofFIG. 7 according to an example embodiment of the present disclosure;

FIG. 10 illustrates an end view of the coupler of the aerosol deliverydevice of FIG. 1 according to an example embodiment of the presentdisclosure;

FIG. 11 schematically illustrates a method for assembling an aerosoldelivery device according to an example embodiment of the presentdisclosure; and

FIG. 12 schematically illustrates a controller according to an exampleembodiment of the present disclosure.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

The present disclosure will now be described more fully hereinafter withreference to exemplary embodiments thereof. These exemplary embodimentsare described so that this disclosure will be thorough and complete, andwill fully convey the scope of the disclosure to those skilled in theart. Indeed, the disclosure may be embodied in many different forms andshould not be construed as limited to the embodiments set forth herein;rather, these embodiments are provided so that this disclosure willsatisfy applicable legal requirements. As used in the specification, andin the appended claims, the singular forms “a”, “an”, “the”, includeplural variations unless the context clearly dictates otherwise.

As described hereinafter, embodiments of the present disclosure relateto aerosol delivery devices. Aerosol delivery devices according to thepresent disclosure may use electrical energy to heat a material(preferably without combusting the material to any significant degree)to form an inhalable substance; such articles most preferably beingsufficiently compact to be considered “hand-held” devices. An aerosoldelivery device may provide some or all of the sensations (e.g.,inhalation and exhalation rituals, types of tastes or flavors,organoleptic effects, physical feel, use rituals, visual cues such asthose provided by visible aerosol, and the like) of smoking a cigarette,cigar, or pipe, without any substantial degree of combustion of anycomponent of that article or device. The aerosol delivery device may notproduce smoke in the sense of the aerosol resulting from by-products ofcombustion or pyrolysis of tobacco, but rather, that the article ordevice most preferably yields vapors (including vapors within aerosolsthat can be considered to be visible aerosols that might be consideredto be described as smoke-like) resulting from volatilization orvaporization of certain components of the article or device. In highlypreferred embodiments, aerosol delivery devices may incorporate tobaccoand/or components derived from tobacco. As such, the aerosol deliverydevice can be characterized as an electronic cigarette.

Aerosol delivery devices of the present disclosure also can becharacterized as being vapor-producing articles or medicament deliveryarticles. Thus, such articles or devices can be adapted so as to provideone or more substances (e.g., flavors and/or pharmaceutical activeingredients) in an inhalable form or state. For example, inhalablesubstances can be substantially in the form of a vapor (i.e., asubstance that is in the gas phase at a temperature lower than itscritical point). Alternatively, inhalable substances can be in the formof an aerosol (i.e., a suspension of fine solid particles or liquiddroplets in a gas). For purposes of simplicity, the term “aerosol” asused herein is meant to include vapors, gases and aerosols of a form ortype suitable for human inhalation, whether or not visible, and whetheror not of a form that might be considered to be smoke-like.

In use, aerosol delivery devices of the present disclosure may besubjected to many of the physical actions employed by an individual inusing a traditional type of smoking article (e.g., a cigarette, cigar orpipe that is employed by lighting and inhaling tobacco). For example,the user of an aerosol delivery device of the present disclosure canhold that article much like a traditional type of smoking article, drawon one end of that article for inhalation of aerosol produced by thatarticle, take puffs at selected intervals of time, etc.

The aerosol delivery device most preferably comprises two or more outerbodies or shells. Existing embodiments of aerosol delivery devicesincluding multiple outer bodies or shells are typically configured suchthat the two or more shells are separable. For example, an aerosoldelivery device can possess at one end a control body comprising anouter body or shell containing one or more reusable components (e.g., arechargeable battery and various electronics for controlling theoperation of that article), and at the other end and removably attachedthereto an outer body or shell containing a disposable portion (e.g., adisposable flavor-containing cartridge).

However, as described hereinafter, embodiments of the present disclosurerelate to aerosol delivery devices comprising multiple shells or outerbodies that may not configured to be separable. In this regard, theaerosol delivery devices of the present disclosure may be disposable insome embodiments. However, in other embodiments the aerosol deliverydevices of the present disclosure may be reusable. For example, a powersource (e.g., a battery) provided therein may be replaceable or theaerosol delivery device may include a rechargeable battery that may berecharged with any type of recharging technology, including connectionto a typical alternating current electrical outlet, connection to a carcharger (e.g., cigarette lighter receptacle), and connection to acomputer, such as through a universal serial bus (USB) connection orcable. Further, a refilling port or other mechanism may allow forrefilling an aerosol precursor composition in some embodiments.

Aerosol delivery devices of the present disclosure most preferablycomprise some combination of a power source (i.e., an electrical powersource), at least one control component (e.g., means for actuating,controlling, regulating and/or ceasing power for heat generation, suchas by controlling electrical current flow from the power source to othercomponents of the aerosol delivery device), a heater or heat generationcomponent (e.g., an electrical resistance heating element or componentcommonly referred to as an “atomizer”), and an aerosol precursorcomposition (e.g., commonly a liquid capable of yielding an aerosol uponapplication of sufficient heat, such as ingredients commonly referred toas “smoke juice,” “e-liquid” and “e-juice”), and a mouthend region ortip for allowing draw upon the aerosol delivery device for aerosolinhalation (e.g., a defined air flow path through the article such thataerosol generated can be withdrawn therefrom upon draw). Exemplaryformulations for aerosol precursor materials that may be used accordingto the present disclosure are described in U.S. Pat. Pub. No.2013/0008457 to Zheng et al. and U.S. Pat. Pub. No. 2013/0213417 toChong et al., the disclosures of which are incorporated herein byreference in their entirety.

Alignment of the components within the aerosol delivery device of thepresent disclosure can vary. In specific embodiments, the aerosolprecursor composition can be located near an end of the aerosol deliverydevice which may be configured to be positioned proximal to the mouth ofa user so as to maximize aerosol delivery to the user. Otherconfigurations, however, are not excluded. Generally, the heatingelement can be positioned sufficiently near the aerosol precursorcomposition so that heat from the heating element can volatilize theaerosol precursor (as well as one or more flavorants, medicaments, orthe like that may likewise be provided for delivery to a user) and forman aerosol for delivery to the user. When the heating element heats theaerosol precursor composition, an aerosol is formed, released, orgenerated in a physical form suitable for inhalation by a consumer. Itshould be noted that the foregoing terms are meant to be interchangeablesuch that reference to release, releasing, releases, or releasedincludes form or generate, forming or generating, forms or generates,and formed or generated. Specifically, an inhalable substance isreleased in the form of a vapor or aerosol or mixture thereof.

As noted above, the aerosol delivery device may incorporate a battery orother electrical power source to provide current flow sufficient toprovide various functionalities to the aerosol delivery device, such aspowering of a heater, powering of control systems, powering ofindicators, and the like. The power source can take on variousembodiments. Preferably, the power source is able to deliver sufficientpower to rapidly heat the heating element to provide for aerosolformation and power the aerosol delivery device through use for adesired duration of time. The power source preferably is sized to fitconveniently within the aerosol delivery device so that the aerosoldelivery device can be easily handled. Additionally, a preferred powersource is of a sufficiently light weight to not detract from a desirablesmoking experience.

More specific formats, configurations and arrangements of componentswithin the aerosol delivery device of the present disclosure will beevident in light of the further disclosure provided hereinafter.Additionally, the selection of various aerosol delivery devicecomponents can be appreciated upon consideration of the commerciallyavailable electronic aerosol delivery devices, such as thoserepresentative products listed in the background art section of thepresent disclosure. Further, the arrangement of the components withinthe aerosol delivery device can also be appreciated upon considerationof the commercially available electronic aerosol delivery devices, suchas those representative products listed in the background art section ofthe present disclosure.

One example embodiment of an aerosol delivery device 100 according tothe present disclosure is illustrated in FIG. 1. In particular, FIG. 1illustrates the aerosol delivery device 100 in an assembledconfiguration. As illustrated, the aerosol delivery device 100 mayinclude a first outer body 102, a second outer body 104, and a coupler106 positioned between and engaged with the first and second outerbodies. In some embodiments the first outer body 102, the second outerbody 104, and/or the coupler 106 may be formed from plastic (e.g.,polycarbonate or acrylonitrile butadiene styrene (ABS)), metal (e.g.,stainless steel or aluminum), paperboard, cardboard, ceramic,fiberglass, glass (e.g., a resilient glass), or a graphite composite. Insome embodiments various attributes of the outer bodies 102, 104 may besimilar to those employed in the control body and cartridge of the VUSE®product available from R. J. Reynolds Tobacco Company. Note that whilethe aerosol delivery device discussed herein is generally described ashaving two outer bodies and a coupler, additional outer bodies may beemployed when respectively connected by an additional coupler.

The coupler 106 may couple the first outer body 102 to the second outerbody 104 in an assembled configuration, as illustrated in FIG. 1. Inthis regard, as illustrated in FIG. 2, the coupler 106 may include afirst engagement portion 108, a second engagement portion 110, and a rib112 positioned therebetween. The first engagement portion 108 of thecoupler 106 may be configured to engage an inner end 102A of the firstouter body 102 (e.g., by insertion therein). In this regard, one or moregaskets 114 (e.g., one or more suitably sized seals, washers, O-rings,or other gasket means for providing sealing and/or resilience, which maycomprise rubber, silicone or other sealant material that is non-reactivewith the aerosol forming components) may be positioned in respectivegrooves 114A (see, FIG. 6) in the first engagement portion 108 of thecoupler 106 and configured to engage an inner surface of the first outerbody 102. Similarly, the second engagement portion 110 of the coupler106 may be configured to engage an inner end 104A of the second outerbody 104 (e.g., by insertion therein). In this regard, one or moregaskets 116 may be positioned in respective grooves 116A (see, FIG. 6)in the second engagement portion 110 of the coupler and configured toengage an inner surface of the second outer body 104.

Accordingly, in some embodiments a press-fit arrangement may be employedto connect the outer bodies 102, 104 to the coupler 106. However,various other connection mechanisms may be employed to couple the outerbodies to the coupler. For example, threaded engagement, an interferencefit, magnetic engagement or other connection mechanisms and arrangementsmay be employed in other embodiments.

The rib 112 of the coupler 106 may be configured to abut the inner end102A of the first outer body 102 and the inner end 104A of the secondouter body 104. Accordingly, as illustrated in FIG. 1, the rib 112 mayseparate the first outer body 102 from the second outer body 104. Assuch, the first outer body 102 and the second outer body 104 may beprevented from making a physical connection (i.e., the first outer bodydoes not directly contact the second outer body). In some embodiments,as illustrated in FIG. 1, the rib 112 may be configured to match anouter profile of the first outer body 102 and the second outer body 104.In this regard, in cylindrical embodiments of the aerosol deliverydevice 100, the diameter of the rib 112 may be substantially equal tothe diameters of the first outer body 102 and the second outer body 104.

The outer bodies 102, 104 may be configured to house and protect aplurality of components received therein, as discussed hereinafter. Theouter bodies 102, 104 may thus define any of a plurality of shapes andconfigurations. However, as described above, in some embodiments it maybe preferable to provide the aerosol delivery device with a size, shape,and/or configuration resembling a smoking article such as a cigarette orcigar. Thus, in some embodiments the outer bodies 102, 104 may begenerally cylindrical and the aerosol delivery device 100 may define anelongated cylindrical configuration as a result of coupler 106 engagingthe inner ends 102A, 104A of the outer bodies 102, 104. The aerosoldelivery device 100 may thus be described as substantially rod-like,substantially tubular shaped, or substantially cylindrically shaped insome embodiments when in the assembled configuration. Accordingly, thetypical size, shape and general appearance of the aerosol deliverydevice 100 may be comparable to commercially available electroniccigarettes.

In some embodiments the outer bodies 102, 104 may define a majority ofan outer surface extending along a longitudinal length of the aerosoldelivery device 100, which may receive a wrapper thereon, as discussedbelow. In this regard, in one embodiment the outer bodies may define atleast 75%, preferably at least 90%, and most preferably 95% of the outersurface extending along a longitudinal length of the aerosol deliverydevice, depending on the length of the dimensions of the end cap 118 andthe mouthpiece 120. Further, in some embodiments the first outer body102 and the second outer body 104 may define substantially the samelongitudinal length. However, in other embodiments the outer bodies 102,104 may define differing longitudinal lengths. For example, a ratio of alongitudinal length of the first outer body 102 to a longitudinal lengthof the second outer body 104 may be from about 2:1 to about 1:2, fromabout 3:5 to about 5:3, or from about 4:5 to about 5:4. In this regard,in some embodiments the dimensions of the first outer body 102 may besimilar to that of a filter element and the dimensions of the secondouter body 104 may be similar to that of a tobacco rod of a traditionalcigarette in some embodiments. This configuration may provide adequateroom in the second outer body 104 for a power source, which may beincluded therein as discussed hereinafter.

As illustrated in FIGS. 1 and 2, an end cap 118 may be coupled to thefirst outer body 102 at an outer end 102B thereof. Further, a mouthpiece120 may be coupled to an outer end 104B of the second outer body 104. Insome embodiments the outer end 102B of the first outer body 102 and/orthe outer end 104B of the second outer body 104B may define a chamfer atthe inner surface thereof, which may facilitate respective coupling ofthe end cap 118 and the mouthpiece 120 thereto.

Briefly, the end cap 118 may be configured to cover and substantiallyprevent access to the outer end 104B of the second outer body 104 and,in some embodiments, provide for output of illumination therethrough.The mouthpiece 120 may be configured to receive a user draw thereonduring use to direct aerosol to the user. In some embodiments a sealantor adhesive such as a room temperature vulcanizing (RTV) sealant, asilicone resin, or a polysiloxane, may seal the end cap 118 to the firstouter body 102 and/or seal the mouthpiece 120 to the second outer body104. The mouthpiece 120 may be textured and/or shaped as desired.Example embodiments of mouthpieces that may be employed in the aerosoldelivery device of the present disclosure are provided in U.S. Pat. Pub.No. 2013/0276802 to Scatterday.

As illustrated in FIG. 3, in some embodiments a wrapper 122 (e.g., alabel or an overwrap) may at least partially surround the outer bodies102, 104. For example, the wrapper 122 may include an overlapping orabutting seam. In one embodiment the wrapper 122 may comprise a singlelayer of a material (e.g., plastic, paper, or foil). Alternatively, thewrapper 122 may comprise a multi-layer lamination (e.g., a lamination ofplastic, paper, and/or foil). The wrapper 122 may include indicia on anouter surface thereof. For example, the indicia may include informationsuch as a product identifier, which may be formed by ink applied to oneor more of the layers of the wrapper 122. The indicia on the wrapper 122likewise may include texturing, coloring, and/or other physicalattributes that may provide a desired appearance to the device, such asresembling a conventional cigarette or a conventional electroniccigarette. Example embodiments of wrappers which may be employed in theaerosol delivery device of the present disclosure are provided in U.S.Pat. Pub. No. 2013/0284190 to Scatterday et al., which is incorporatedherein by reference in its entirety.

The wrapper 122 may include an adhesive at an inner surface thereof oradhesive may otherwise be positioned between the wrapper and the outerbodies 102, 104. Thus, the wrapper 122 may be secured to an outersurface of the outer bodies 102, 104. In this regard, embodiments of thepresent disclosure may include at least one securing mechanismconfigured to substantially irreversibly secure the first outer body 102to the second outer body 104. In some embodiments the securing mechanismmay comprise the above-described wrapper 122. Thus, when adhered to thefirst outer body 102 and the second outer body 104, the wrapper 122 mayact as a structural member that assists in retaining the couplingbetween the outer bodies via the coupler 106. For example, in theillustrated embodiment, the wrapper 122 extends from the outer end 102Bof the first outer body 102 to the outer end 104B of the second outerbody 104, such that coupling between the wrapper and the first andsecond outer bodies retains the aerosol delivery device 100 in theassembled configuration. Additionally, in embodiments in which thecoupler 106 includes the rib 112, contact between the wrapper 122 andthe rib may further assist in maintaining the aerosol delivery device inthe assembled configuration. Further, in some embodiments the wrapper122 may extend at least partially over the end cap 118 to secure the endcap to the first outer body 102 and/or extend at least partially overthe mouthpiece 120 to secure the mouthpiece to the second outer body104.

Although the securing mechanism is described above as comprising thewrapper 122, various other embodiments of securing mechanisms configuredto substantially irreversibly secure the first outer body 102 to thesecond outer body 104 may be employed. Thus, for example, the securingmechanism may comprise sealant applied between the coupler 106 and oneor both of the outer bodies 102, 104. By way of further example, thesecuring mechanism may comprise single-use connectors at the coupler 106configured to engage the outer bodies 102, 104. In another embodimentthe securing mechanism may comprise other connection mechanisms (e.g.,welds, crimps, or solder), that cause portions of the outer bodies 102,104 to engage the coupler 106. Note that substantially irreversiblysecured, as used herein, refers to a configuration in which the outerbodies 102, 104 may not be separated from one another without damagingthe securing mechanism and/or without preventing recoupling of thereferenced components. Thus, for example, the wrapper 122 may be torn orotherwise damaged if the outer bodies 102, 104 of the aerosol deliverydevice 100 were to be separated.

FIG. 4 illustrates an exploded view of the aerosol delivery device 100.As illustrated, the aerosol delivery device 100 may include a pluralityof additional components as described in greater detail hereinafter. Inthis regard, the aerosol delivery device 100 may additionally include amouthpiece shipping plug 124 which may be configured to engage andprotect the mouthpiece 120 prior to use of the aerosol delivery device.For example, the mouthpiece shipping plug 120 may prevent the entry ofcontaminants into the mouthpiece 120. Thus, the mouthpiece shipping plug120 may be removed prior to use of the aerosol delivery device 100.

Further, a plurality of components may be positioned in one or both ofthe first outer body 102 and the second outer body 104. In this regard,a reservoir substrate 126, an atomizer 128, and a flow director 130(e.g., a flow tube or other structure defining an airflow passage) maybe positioned in the second outer body 104. The atomizer 128 may includea liquid transport element 132 with a heating element 134 coupledthereto.

Further, a power source 136 and an electrical circuit 138 may bepositioned in the first outer body 102. Examples of power sources aredescribed in U.S. Pat. App. Pub. No. 2010/0028766 by Peckerar et al.,the disclosure of which is incorporated herein by reference in itsentirety. The electrical circuit 138 may include a control module 140, aspacer 142, and/or a safety switch 144 in some embodiments. One or moreelectrical connectors 146 (e.g., electrical wires) may be configured toelectrically connect the atomizer 128 to the power source 136. In thisregard, the electrical connectors 146 may extend between the first outerbody 102 and the second outer body 104 through the coupler 106 in theassembled configuration. In one embodiment one or more electricalcouplers 148 (e.g., brass couplers, solder, crimped couplers, or woundwires) may be employed to couple the electrical connectors 146 to theheating element 134. Thus, in some embodiments the electrical couplers148 may be received in the second outer body 104.

In terms of operation of the aerosol delivery device 100, a user maydraw on the mouthpiece 120. Accordingly, air may enter the aerosoldelivery device 100 through an inlet aperture. For example, in theillustrated embodiment, an inlet aperture 150 (see, e.g., FIG. 1) isdefined in the first outer body 102. However, in other embodiments theinlet aperture may be defined in the second outer body. Note that inembodiments of the aerosol delivery device 100 including the wrapper122, a cutout 152 (see, FIG. 3) may align with the inlet aperture 150such that the inlet aperture is not blocked. Alternatively, the wrappermay be substantially air-permeable, particularly in the area adjacentthe inlet aperture, so as to allow sufficient air passage therethroughand into the aperture.

Air entering through the inlet aperture 150 in the first outer body 102may be directed through the coupler 106 to the second outer body 104. Inthis regard, as illustrated in FIG. 5, the inlet aperture 150 may alignwith a recessed portion 154 defined at a peripheral surface 155 of thefirst engagement portion 108 of the coupler 106. Note that alignment ofthe recessed portion 154 of the coupler 106 may only requirelongitudinal alignment of the inlet aperture 150 with the recessedportion, along the longitudinal length of the aerosol delivery device100. In this regard, in some embodiments the recessed portion 154 mayextend around the peripheral surface 155 of the coupler 106 (e.g.,around the entirety of the circumference thereof). Further, asillustrated, in some embodiments the inlet aperture 150 and the recessedportion 154 may be configured to align when the inner end 102A of thefirst outer body 102 abuts the rib 112. Accordingly, alignment of theinlet aperture 150 with the recessed portion 154 may be substantiallyeasily achieved during assembly. Air received in the recessed portion154 of the coupler 106 may be directed through one or more couplerinlet(s) 156 defined in the coupler 106 at the recessed portion.

FIG. 6 illustrates a cross-sectional view through the coupler 106 alongline A-A in FIG. 5. As illustrated in FIG. 6, the coupler inlet 156 mayconnect to a longitudinal channel 158 extending along at least a portionof the longitudinal length of the coupler 106. Further, a pressure port160 may additionally be in communication with the coupler inlet 156and/or the longitudinal channel 158. The pressure port 160 may extend toa pressure port opening 162 positioned inside the first outer body 102when the coupler 106 is connected thereto.

Accordingly, the control module 140 (see, FIG. 4) may detect when a userdraws on the mouthpiece 120. In this regard, the control module 140 maycomprise a sensor configured to detect a puff. For example, a pressuresensor may be used to detect a pressure drop accompanying a draw on themouthpiece 120. Representative current regulating components and othercurrent controlling components including various microcontrollers foraerosol delivery devices are described in U.S. Pat. No. 4,735,217 toGerth et al., U.S. Pat. Nos. 4,922,901, 4,947,874, and 4,947,875, all toBrooks et al., U.S. Pat. No. 5,372,148 to McCafferty et al., U.S. Pat.No. 6,040,560 to Fleischhauer et al., U.S. Pat. No. 7,040,314 to Nguyenet al., and U.S. Pat. No. 8,205,622 to Pan, all of which areincorporated herein by reference in their entireties. Reference also ismade to the control schemes described in U.S. application Ser. No.13/837,542 to Ampolini et al., filed Mar. 15, 2013, which isincorporated herein by reference in its entirety. In some embodiments, apressure sensor and a microcontroller may be combined in control module140.

Thus, as a result of the control module 140 being positioned in thefirst outer body 102, a drop in pressure may be detected when a userdraws on the aerosol delivery device 100. In this regard, the firstouter body 102 may be substantially sealed as a result of the end cap118 being positioned at the outer end 102B and the gaskets 114 beingpositioned at the inner end 102A of the outer body (see, e.g., FIG. 4).Thereby, the pressure drop associated with the puff on the aerosoldelivery device 100 may be detected, but airflow through the first outerbody 102 may be substantially avoided, since the first outer body issubstantially sealed other than at the pressure port 160.

Airflow in the above described manner is designed to avoid airflow pastthe power source 136. Further, note that a size of the pressure portopening 162 (e.g., a diameter thereof) may be smaller than a diameter ofa coupler outlet opening 164 (see, FIG. 6) in communication with thesecond outer body 104. Accordingly, a Venturi effect may be createdduring a draw on the aerosol delivery device 100, which further assistsin preventing airflow through the first outer body 102 while stillallowing detection of a pressure drop therein.

Thus, as noted above, the control module 140 may sense a puff on theaerosol delivery device 100. When the puff is sensed, control module 140may direct current from the power source 136 through the electricalconnectors 146 to the heating element 134. Thus, as described in greaterdetail below, the heating element 134 may vaporize an aerosol precursorcomposition directed from the reservoir substrate 126 to the heatingelement via the liquid transport element 132. Accordingly, the heatingelement 134 may vaporize the aerosol precursor composition directed toan aerosolization zone from the reservoir substrate 126 by the liquidtransport element 132 and air and the entrained vapor (e.g., thecomponents of the aerosol precursor composition in an inhalable form)may be directed to a user drawing thereon.

The safety switch 144 may be configured to control or stop the flow ofcurrent to the heating element 134 under certain circumstances. Forexample, the safety switch may be configured to stop the flow of currentto the heating element 134 after a predetermined length of time,regardless of whether a detected puff continues, in order to prevent theheating element 134 from overheating. Accordingly, issues with respectto the aerosol delivery device 100 overheating may be avoided.

In some embodiments the control module 140 may perform additionalfunctions. For example, the control module 140 may also include anoptional indicator (e.g., a light emitting diode (LED)). The indicatormay illuminate, for example, during a user drawing on the aerosoldelivery device, as detected by the control module 140. The end cap 118may be adapted to make visible the illumination provided thereunder bythe indicator. Accordingly, the indicator may illuminate during use ofthe aerosol delivery device 100 to simulate the lit end of a smokingarticle. However, in other embodiments the indicator can be provided invarying numbers and can take on different shapes and can even be anopening in the outer body (such as for release of sound when suchindicators are present).

As noted above, air received through the inlet aperture 150 in the firstouter body 102 may be directed through the recessed portion 154, thecoupler inlet 156, and the longitudinal channel 158 extending along atleast a portion of the longitudinal length of the coupler 106. Thereby,the air may be directed to the flow director 130. The flow director 130may define a tubular configuration or other structure in which an airpassageway is defined therethrough. In this regard, as illustrated inFIGS. 5 and 6, the coupler 106 may define a nipple 166.

Further, as illustrated in FIG. 7, the nipple 166 may couple to the flowdirector 130. For example, the flow director 130 may extend over thenipple 166 to provide for engagement therebetween. In this regard, theflow director 130 may comprise a flexible, resilient material such asfiberglass which may deform (e.g., stretch) slightly to allow forreceipt of the nipple 166 therein and fit snuggly over the nipple andform a seal therewith. Accordingly, air received from the coupler 106may be directed through a longitudinal aperture 168 defined through theflow director 130.

Thus, drawn air through the device is directed past the heating element134. More particularly, as illustrated in FIG. 8, the flow director 130may define a transverse aperture 170 extending therethrough. Asillustrated, the transverse aperture 170 may extend substantiallyperpendicularly to the longitudinal aperture 168. As illustrated in FIG.7, the atomizer 128 may extend through the transverse aperture 170.Thereby, the heating element 134 may be positioned in the longitudinalaperture 168 extending along the length of the flow director 130. Moreparticularly, the heating element 134 may extend transversely relativeto the longitudinal aperture 168 such that at least a portion of theheating element is positioned in the longitudinal aperture.

In some embodiments, in order to facilitate insertion of the atomizer128 in the transverse aperture 170, a slit 172 may be defined in theflow director 130. The slit 172 may extend from an outer surface of theflow director 130 to the transverse aperture 170. For example, asillustrated in FIG. 7, the slit 172 may define a V-shape. Thereby,during assembly, the flow director 130 may be folded at the slit 172 tofacilitate insertion of the atomizer 128 into the transverse aperture170, rather than inserted lengthwise through the transverse aperture170. For example, the heating element 134 may catch on the flow director130 during lengthwise insertion of the atomizer 128 when longitudinalinsertion is employed. Thus, use of the slit 172 may expedite assemblyof the aerosol delivery device 100 by allowing for coupling of theatomizer 128 to the flow director 130 without requiring lengthwiseinsertion of the atomizer 128 through the transverse aperture 170.

Following insertion of the atomizer 128 into the transverse aperture170, the flow director 130 may be folded back into the originallongitudinal (e.g., tubular) configuration. Accordingly, as illustratedin FIG. 9, the heating element 134 may be at least partially positionedwithin the longitudinal aperture 168 extending through the flow director130. Thus, drawn air received from the coupler 106 during a user puffmay be directed by the flow director 130 past the heating element 134before being directed by the longitudinal aperture 168 to the mouthpiece120, as illustrated in FIG. 7. In this regard, the mouthpiece 120 maydefine a nipple 174. Thus, the flow director 130 may extend over thenipple 174 to provide for engagement therebetween. As noted above, theflow director 130 may comprise a flexible, resilient material such asfiberglass which may deform (e.g., stretch) slightly to allow forreceipt of the nipple 174 therein. Accordingly, air traveling throughthe longitudinal aperture 168 defined through the flow director 130 maybe directed through the mouthpiece 120 and to a user's mouth.

As illustrated in FIG. 9, the flow director 130 may extend at leastpartially through the reservoir substrate 126 so as to define an airpassageway therethrough. Further, as illustrated in FIGS. 8 and 9, theliquid transport element 132 may define a center portion 176 and firstand second opposing arms 178A, 178B extending therefrom. The heatingelement 134 may be coupled to the center portion 176 of the liquidtransport element 132.

The opposing arms 178A, 178B of the liquid transport element 134 may beconfigured to direct an aerosol precursor composition to the heatingelement 134. In this regard, the reservoir substrate 126 may beconfigured to hold (e.g., support, carry, and/or store) an aerosolprecursor composition therein. The aerosol precursor composition, alsoreferred to as a vapor precursor composition, may comprise a variety ofcomponents including, by way of example, a polyhydric alcohol (e.g.,glycerin, propylene glycol, or a mixture thereof), nicotine, tobacco,tobacco extract, and/or flavorants. Various components that may beincluded in the aerosol precursor composition are described in U.S. Pat.No. 7,726,320 to Robinson et al., which is incorporated herein byreference in its entirety. Additional representative types of aerosolprecursor compositions are set forth in U.S. Pat. No. 4,793,365 toSensabaugh, Jr. et al.; U.S. Pat. No. 5,101,839 to Jakob et al.; PCT WO98/57556 to Biggs et al.; and Chemical and Biological Studies on NewCigarette Prototypes that Heat Instead of Burn Tobacco, R. J. ReynoldsTobacco Company Monograph (1988); the disclosures of which areincorporated herein by reference in their entireties. Other aerosolprecursors which may be employed in the aerosol delivery device 100include the aerosol precursors included in the VUSE® product by R. J.Reynolds Vapor Company, the BLU™ product by Lorillard Technologies, theMistic Menthol product by Mistic Ecigs, and the Vype product by CNCreative Ltd. Also desirable are the so-called “Smoke Juices” forelectronic cigarettes that have been available from Johnson CreekEnterprises LLC.

The reservoir substrate 126 may comprise one layer or a plurality oflayers of woven or nonwoven fibers (e.g., C-glass, E-glass) formed intothe shape of a tube encircling the interior of the second outer body104. Thus, liquid components, for example, can be sorptively retained bythe reservoir substrate 126. The reservoir substrate 126 is in fluidconnection with the liquid transport element 132. In this regard, theopposing arms 178A, 178B may be positioned between the flow director 130and the reservoir substrate 126. Accordingly, contact between the liquidtransport element 132 and the reservoir substrate 126 may allow forfluid transfer therebetween. Thus, the liquid transport element 132 maybe configured to transport liquid from the reservoir substrate 126 tothe heating element 134 (e.g., via wicking or capillary action). In FIG.9, a space is present between the reservoir substrate 126 and the flowdirector 130 for accommodating the opposing arms 178A, 178B. In otherembodiments, the reservoir substrate 126 may be in substantial contactwith the flow director 130 around at least a portion of thecircumference of the flow director. As such, at least a portion of theopposing arms 178A, 178B may be substantially flattened between thereservoir substrate and the flow director. Exemplary reservoirs formedof cellulose acetate fibers and liquid transport elements that may beused herein as described in U.S. patent application Ser. No. 13/802,950to Chapman et al., filed Mar. 14, 2013, which is incorporated herein byreference in its entirety.

As illustrated in FIG. 9, the liquid transport element 132 may be indirect contact with the heating element 134. As further illustrated inFIG. 9, the heating element 134 may comprise a wire defining a pluralityof coils (e.g., from about 4 coils to about 12 coils) wound about theliquid transport element 132. In some embodiments the heating element134 may be formed by winding the wire about the liquid transport element132 as described in U.S. patent application Ser. No. 13/708,381 to Wardet al., filed Dec. 7, 2012, which is incorporated herein by reference inits entirety. Further, in some embodiments the wire may define avariable coil spacing, as described in U.S. patent application Ser. No.13/827,994 to DePiano et al., filed Mar. 14, 2013, which is incorporatedherein by reference in its entirety. Various embodiments of materialsconfigured to produce heat when electrical current is appliedtherethrough may be employed to form the heating element 134. Examplematerials from which the wire coil may be formed include Kanthal(FeCrAl), Nichrome, Molybdenum disilicide (MoSi₂), molybdenum silicide(MoSi), Molybdenum disilicide doped with Aluminum (Mo(Si,Al)₂), graphiteand graphite-based materials; and ceramic (e.g., a positive or negativetemperature coefficient ceramic).

However, various other embodiments of methods may be employed to formthe heating element 134, and various other embodiments of heatingelements may be employed in the atomizer 128. For example, a stampedheating element may be employed in the atomizer, as described in U.S.patent application Ser. No. 13/842,125 to DePiano et al., filed Mar. 15,2013, which is incorporated herein by reference in its entirety. Furtherto the above, additional representative heating elements and materialsfor use therein are described in U.S. Pat. No. 5,060,671 to Counts etal.; U.S. Pat. No. 5,093,894 to Deevi et al.; U.S. Pat. No. 5,224,498 toDeevi et al.; U.S. Pat. No. 5,228,460 to Sprinkel Jr., et al.; U.S. Pat.No. 5,322,075 to Deevi et al.; U.S. Pat. No. 5,353,813 to Deevi et al.;U.S. Pat. No. 5,468,936 to Deevi et al.; U.S. Pat. No. 5,498,850 to Das;U.S. Pat. No. 5,659,656 to Das; U.S. Pat. No. 5,498,855 to Deevi et al.;U.S. Pat. No. 5,530,225 to Hajaligol; U.S. Pat. No. 5,665,262 toHajaligol; U.S. Pat. No. 5,573,692 to Das et al.; and U.S. Pat. No.5,591,368 to Fleischhauer et al., and U.S. Pat. Pub. No. 2013/0192618 toLi et al., the disclosures of which are incorporated herein by referencein their entireties. Further, chemical heating may be employed in otherembodiments. Various additional examples of heaters and materialsemployed to form heaters are described in U.S. patent application Ser.No. 13/602,871 to Collett et al., filed Sep. 4, 2012, which isincorporated herein by reference, as noted above. Additionally, invarious embodiments, one or more microheaters or like solid stateheaters may be used.

Note that, as illustrated in FIG. 7, the heating element 134 may bepositioned relatively closer to the coupler 106 than the mouthpiece 120.This configuration may be preferable in that it provides a separationbetween a user's mouth and the heating element 134, which produces heatduring use. Accordingly, as a result of the heating element 134 beingpositioned proximate the coupler 106, the opposing arms 178A, 178B maybe folded away from the coupler 106 in order for the liquid transportelement 132 to remain in contact with a significant portion of thereservoir substrate 126. This configuration may also result in the oneor more electrical connectors 146 extending in an opposite direction ascompared to the opposing arms 178A, 178B of the liquid transport element132, toward the coupler 106, with the electrical couplers 148 connectingthe heating element 134 to the electrical connectors 146.

In this regard, FIG. 10 illustrates a view of the coupler 106 at an endconfigured to engage the first outer body 102. As illustrated, one ormore connector apertures 180 may extend through a longitudinal length ofthe coupler 106. Accordingly, the electrical connectors 146 may extendfrom the first outer body 102 through the connector apertures 180 to thesecond outer body 104 in order to connect the atomizer 128 to the powersource 136.

Still further components can be utilized in the aerosol delivery device100 of the present disclosure. For example, U.S. Pat. No. 5,154,192 toSprinkel et al. and U.S. Pat. No. 8,539,959 to Scatterday discloseindicators and LEDs for smoking articles; U.S. Pat. No. 5,261,424 toSprinkel, Jr. discloses piezoelectric sensors that can be associatedwith the mouth-end of a device to detect user lip activity associatedwith taking a draw and then trigger heating; U.S. Pat. No. 5,372,148 toMcCafferty et al. discloses a puff sensor for controlling energy flowinto a heating load array in response to pressure drop through amouthpiece; U.S. Pat. No. 5,967,148 to Harris et al. disclosesreceptacles in a smoking device that include an identifier that detectsa non-uniformity in infrared transmissivity of an inserted component anda controller that executes a detection routine as the component isinserted into the receptacle; U.S. Pat. No. 6,040,560 to Fleischhauer etal. describes a defined executable power cycle with multipledifferential phases; U.S. Pat. No. 5,934,289 to Watkins et al. disclosesphotonic-optronic components; U.S. Pat. No. 5,954,979 to Counts et al.discloses means for altering draw resistance through a smoking device;U.S. Pat. No. 6,803,545 to Blake et al. discloses specific batteryconfigurations for use in smoking devices; U.S. Pat. No. 7,293,565 toGriffen et al. discloses various charging systems for use with smokingdevices; U.S. Pat. No. 8,402,976 to Fernando et al. discloses computerinterfacing means for smoking devices to facilitate charging and allowcomputer control of the device; U.S. Pat. App. Pub. No. 2010/0163063 byFernando et al. discloses identification systems for smoking devices;and WO 2010/003480 by Flick discloses a fluid flow sensing systemindicative of a puff in an aerosol generating system; all of theforegoing disclosures being incorporated herein by reference in theirentireties. Further examples of components related to electronic aerosoldelivery articles and disclosing materials or components that may beused in the present article include U.S. Pat. No. 4,735,217 to Gerth etal.; U.S. Pat. No. 5,249,586 to Morgan et al.; U.S. Pat. No. 5,666,977to Higgins et al.; U.S. Pat. No. 6,053,176 to Adams et al.; U.S. Pat.No. 6,164,287 to White; U.S. Pat. No. 6,196,218 to Voges; U.S. Pat. No.6,810,883 to Felter et al.; U.S. Pat. No. 6,854,461 to Nichols; U.S.Pat. No. 7,832,410 to Hon; U.S. Pat. No. 7,513,253 to Kobayashi; U.S.Pat. No. 7,896,006 to Hamano; U.S. Pat. No. 6,772,756 to Shayan; U.S.Pat. Nos. 8,156,944 and 8,375,957 to Hon; U.S. Pat. App. Pub. Nos.2006/0196518 and 2009/0188490 to Hon; U.S. Pat. App. Pub. No.2009/0272379 to Thorens et al.; U.S. Pat. App. Pub. Nos. 2009/0260641and 2009/0260642 to Monsees et al.; U.S. Pat. App. Pub. Nos.2008/0149118 and 2010/0024834 to Oglesby et al.; U.S. Pat. App. Pub. No.2010/0307518 to Wang; WO 2010/091593 to Hon; WO 2013/089551 to Foo; andU.S. patent application Ser. No. 13/841,233 to DePiano et al., filedMar. 15, 2013, each of which is incorporated herein by reference in itsentirety. A variety of the materials disclosed by the foregoingdocuments may be incorporated into the present devices in variousembodiments, and all of the foregoing disclosures are incorporatedherein by reference in their entireties.

Various other details with respect to the components that may beincluded in the aerosol delivery device, are provided, for example, inU.S. patent application Ser. No. 13/840,264 to Novak et al., filed Mar.15, 2013, U.S. Pat. No. 8,365,742 to Hon; U.S. Pat. Pub. Nos.2013/0192623 to Tucker et al., 2013/0298905 to Leven et al., and2013/0180553 to Kim et al., each of which is incorporated herein byreference in its entirety. Reference is also made, for example, to thereservoir and heater system for controllable delivery of multipleaerosolizable materials in an electronic smoking article disclosed inU.S. Pat. App. Pub. No. 2014/0000638 to Sebastian et al., which isincorporated herein by reference in its entirety.

Additionally, various components of an aerosol delivery device accordingto the present disclosure can be chosen from components described in theart and that have been commercially available. In this regard,representative products that resemble many of the attributes oftraditional types of cigarettes, cigars or pipes have been marketed asACCORD® by Philip Morris Incorporated; ALPHA™, JOYE 510™ and M4™ byInnoVapor LLC; CIRRUS™ and FLING™ by White Cloud Cigarettes; BLU™ byLorillard Technologies, Inc.; COHITA™, COLIBRI™, ELITE CLASSIC™,MAGNUM™, PHANTOM™ and SENSE™ by Epuffer® International Inc.; DUOPRO™,STORM™ and VAPORKING® by Electronic Cigarettes, Inc.; EGAR™ by EgarAustralia; eGo-C™ and eGo-T™ by Joyetech; ELUSION™ by Elusion UK Ltd;EONSMOKE® by Eonsmoke LLC; FIN™ by FIN Branding Group, LLC; SMOKE® byGreen Smoke Inc. USA; GREENARETTE™ by Greenarette LLC; HALLIGAN™,HENDU™, JET™, MAXXQ™, PINK™ and PITBULL™ by Smoke Stik®; HEATBAR™ byPhilip Morris International, Inc.; HYDRO IMPERIAL™ and LXE™ from Crown7;LOGIC™ and THE CUBAN™ by LOGIC Technology; LUCI® by Luciano Smokes Inc.;METRO® by Nicotek, LLC; NJOY® and ONEJOY™ by Sottera, Inc.; NO. 7™ by SSChoice LLC; PREMIUM ELECTRONIC CIGARETTE™ by PremiumEstore LLC; RAPPE-MYSTICK™ by Ruyan America, Inc.; RED DRAGON™ by Red Dragon Products,LLC; RUYAN® by Ruyan Group (Holdings) Ltd.; SF® by Smoker FriendlyInternational, LLC; GREEN SMART SMOKER® by The Smart Smoking ElectronicCigarette Company Ltd.; SMOKE ASSIST® by Coastline Products LLC; SMOKINGEVERYWHERE® by Smoking Everywhere, Inc.; V2CIGS™ by VMR Products LLC;VAPOR NINE™ by VaporNine LLC; VAPOR4LIFE® by Vapor 4 Life, Inc.; VEPPO™by E-CigaretteDirect, LLC; VUSE® by R. J. Reynolds Vapor Company; MisticMenthol product by Mistic Ecigs; and the Vype product by CN CreativeLtd. Yet other electrically powered aerosol delivery devices, and inparticular those devices that have been characterized as so-calledelectronic cigarettes, have been marketed under the tradenames COOLERVISIONS™; DIRECT E-CIG™; DRAGONFLY™; EMIST™; EVERSMOKE™; GAMUCCI®;HYBRID FLAME™; KNIGHT STICKS™; ROYAL BLUES™; SMOKETIP®; SOUTH BEACHSMOKE™.

Additional manufacturers, designers, and/or assignees of components andrelated technologies that may be employed in the aerosol delivery deviceof the present disclosure include Shenzhen Jieshibo Technology ofShenzhen, China; Shenzhen First Union Technology of Shenzhen City,China; Safe Cig of Los Angeles, Calif.; Janty Asia Company of thePhilippines; Joyetech Changzhou Electronics of Shenzhen, China; SISResources; B2B International Holdings of Dover, Del.; Evolv LLC of OH;Montrade of Bologna, Italy; Shenzhen Bauway Technology of Shenzhen,China; Global Vapor Trademarks Inc. of Pompano Beach, Fla.; Vapor Corp.of Fort Lauderdale, Fla.; Nemtra GMBH of Raschau-Markersbach, Germany,Perrigo L. Co. of Allegan, Mich.; Needs Co., Ltd.; Smokefree Innotec ofLas Vegas, Nev.; McNeil AB of Helsingborg, Sweden; Chong Corp; AlexzaPharmaceuticals of Mountain View, Calif.; BLEC, LLC of Charlotte, N.C.;Gaitrend Sarl of Rohrbach-les-Bitche, France; FeelLife BioscienceInternational of Shenzhen, China; Vishay Electronic BMGH of Selb,Germany; Shenzhen Smaco Technology Ltd. of Shenzhen, China; VaporSystems International of Boca Raton, Fla.; Exonoid Medical Devices ofIsrael; Shenzhen Nowotech Electronic of Shenzhen, China; MinilogicDevice Corporation of Hong Kong, China; Shenzhen Kontle Electronics ofShenzhen, China, and Fuma International, LLC of Medina, Ohio, and 21stCentury Smoke of Beloit, Wis.

In another embodiment, part or substantially all of the aerosol deliverydevice may be formed from one or more carbon materials, which mayprovide advantages in terms of biodegradability and absence of wires. Inthis regard, the heating element may comprise carbon foam, the reservoirmay comprise carbonized fabric, and graphite may be employed to form anelectrical connection with the battery and controller. An exampleembodiment of a carbon-based cartridge is provided in U.S. Pat. App.Pub. No. 2013/0255702 to Griffith et al., which is incorporated hereinby reference in its entirety.

Note that in the embodiment of the aerosol delivery device 100 describedabove, first and second outer bodies 102, 104 are employed. Use of twoor more outer bodies may be advantageous in a number of respects. Forexample, the components may be assembled in each of the outer bodies102, 104 separately. Thus, for example, components may be assembled inthe first outer body 102 at a separate time and/or location as comparedto assembly of the components in the second outer body 104. Thus, forexample, the outer bodies 102, 104 may be assembled with theirrespective components under different conditions in some embodiments.For example, it may be desirable to assemble components in the secondouter body 104 under controlled conditions to avoid contamination of theflow path or undesirable absorption of moisture in the reservoirsubstrate 126, which may cause leaks or affect the resulting aerosol.

Further, separate assembly of the components in the outer bodies 102,104 may additionally allow for final assembly of the aerosol deliverydevice 100 at an alternate location and/or time, if desirable. Forexample, a consumer may be provided with the outer bodies 102, 104respectively having the components assembled therein, and final assemblymay be completed by the consumer. Further, enhanced customization of theaerosol delivery device 100 and/or supply chain management may beprovided by use of separate outer bodies 102, 104. In this regard, forexample, multiple embodiments of components may be received in one orboth of the outer bodies 102, 104. Thus for example, the first outerbody 102 may be provided with either regular or extended capacity powersources 136, which may be employed irrespective of the componentsreceived in the second outer body 104. Conversely, the second outer body104 may include reservoir substrates 126 having any of varyingcapacities and/or types of aerosol precursor compositions receivedtherein. Thus, various embodiments of aerosol delivery devices 100 maybe formed simply by selecting the appropriate desired embodiment ofouter bodies 102, 104, which may be respectively assembled in advance,rather than specifically assembled to suit demand. As may be understood,the coupler 106 may additionally provide and/or facilitate theabove-noted benefits by allowing for coupling of the outer bodies 102,104. Further, the coupler 106 may be coupled to one of the outer bodies102, 104 in advance of completion of the aerosol delivery device 100 inorder to complete a section of the aerosol delivery device. Accordingly,the embodiments of aerosol delivery devices including multiple outerbodies as provided herein may provide benefits over existing embodimentsof aerosol delivery devices that include a single, unitary housing, suchas those embodiments of aerosol delivery devices disclosed in U.S. Pat.Nos. 8,364,742 and 8,393,331 to Hon, which are incorporated herein byreference in their entireties. Additional examples of aerosol deliverydevices including a single, unitary housing are commercially availableVype™ by CN Creative, LTD and NJOY® by Sottera, Inc.

A method for assembling an aerosol delivery device is also provided. Asillustrated in FIG. 11, the method may include positioning a powersource in a first outer body defining an inlet aperture at operation202. Further, the method may include positioning an atomizer in a secondouter body at operation 204. The method may additionally includeengaging a coupler defining a coupler inlet and a longitudinal channelwith the first outer body and the second outer body such that thecoupler is positioned to receive air from the inlet aperture defined inthe first outer body through the coupler inlet and to direct the airthrough the longitudinal channel to the second outer body at operation206.

In some embodiments the method may further comprise substantiallyirreversibly securing the first outer body to the second outer body witha securing mechanism. Substantially irreversibly securing the firstouter body to the second outer body with the securing mechanism maycomprise wrapping a wrapper at least partially around the first outerbody, the second outer body, and the coupler. The method mayadditionally include positioning a reservoir substrate and a flowdirector in the second outer body such that the flow director extends atleast partially through the reservoir substrate. Positioning theatomizer in the second outer body may comprise inserting the atomizerthrough a transverse aperture extending through the flow director.

The method may further comprise inserting a plurality of electricalconnectors through the coupler and connecting the electrical connectorsto the power source and the atomizer. The method may additionallyinclude coupling a heating element to a center portion of a liquidtransport element to form the atomizer and folding first and secondopposing arms of the liquid transport element extending from the centersection away from the coupler.

In some embodiments the method may further comprise coupling the flowdirector to a nipple of the coupler. The method may also includecoupling the flow director to a nipple of a mouthpiece. Further,engaging the coupler with the first outer body and the second outer bodyat operation 206 may comprise engaging a rib of the coupler with thefirst outer body and the second outer body.

In an additional embodiment a controller configured to assemble theaerosol delivery device 100 of the present disclosure is provided. Thecontroller may be configured to execute computer code for performing theoperations described herein. In this regard, as illustrated in FIG. 12,the controller 300 may comprise a processor 302 that may be amicroprocessor or a controller for controlling the overall operationthereof. In one embodiment the processor 302 may be particularlyconfigured to perform the functions described herein, including theoperations for assembling the aerosol delivery device 100 of the presentdisclosure. The controller 300 may also include a memory device 304. Thememory device 304 may include non-transitory and tangible memory thatmay be, for example, volatile and/or non-volatile memory. The memorydevice 304 may be configured to store information, data, files,applications, instructions or the like. For example, the memory device304 could be configured to buffer input data for processing by theprocessor 302. Additionally or alternatively, the memory device 304 maybe configured to store instructions for execution by the processor 302.

The controller 300 may also include a user interface 306 that allows auser to interact therewith. For example, the user interface 306 can takea variety of forms, such as a button, keypad, dial, touch screen, audioinput interface, visual/image capture input interface, input in the formof sensor data, etc. Still further, the user interface 306 may beconfigured to output information to the user through a display, speaker,or other output device. A communication interface 308 may provide fortransmitting and receiving data through, for example, a wired orwireless network 310 such as a local area network (LAN), a metropolitanarea network (MAN), and/or a wide area network (WAN), for example, theInternet.

The various aspects, embodiments, implementations or features of thedescribed embodiments can be used separately or in any combination.Various aspects of the described embodiments can be implemented bysoftware, hardware or a combination of hardware and software. Thedescribed embodiments can also be embodied as computer readable code ona computer readable medium for controlling the above-describedoperations. In particular, computer readable code may be configured toperform each of the operations of the methods described herein andembodied as computer readable code on a computer readable medium forcontrolling the above-described operations. In this regard, a computerreadable storage medium, as used herein, refers to a non-transitory,physical storage medium (e.g., a volatile or non-volatile memory device,which can be read by a computer system. Examples of the computerreadable medium include read-only memory, random-access memory, CD-ROMs,DVDs, magnetic tape, and optical data storage devices. The computerreadable medium can also be distributed over network-coupled computersystems so that the computer readable code is stored and executed in adistributed fashion.

As noted above, the controller 300 may be configured to execute computercode for performing the above-described assembly operations. In thisregard, an embodiment of a non-transitory computer readable medium forstoring computer instructions executed by a processor in a controller(e.g. controller 300) configured to assemble an aerosol delivery deviceis provided. The non-transitory computer readable medium may compriseprogram code instructions for positioning a power source in a firstouter body defining an inlet aperture, program code instructions forpositioning an atomizer in a second outer body, and program codeinstructions for engaging a coupler defining a coupler inlet and alongitudinal channel with the first outer body and the second outer bodysuch that the coupler is positioned to receive air from the inletaperture defined in the first outer body through the coupler inlet andto direct the air through the longitudinal channel to the second outerbody.

In some embodiments the computer readable medium may further compriseprogram code instructions for substantially irreversibly securing thefirst outer body to the second outer body with a securing mechanism. Theprogram code instructions for substantially irreversibly securing thefirst outer body to the second outer body with the securing mechanismmay comprise program code instructions for wrapping a wrapper at leastpartially around the first outer body, the second outer body, and thecoupler. The computer readable medium may further comprise program codeinstructions for positioning a reservoir substrate and a flow directorin the second outer body such that the flow director extends at leastpartially through the reservoir substrate. The program code instructionsfor positioning the atomizer in the second outer body may compriseprogram code instructions for inserting the atomizer through atransverse aperture extending through the flow director.

The computer readable medium may further comprise program codeinstructions for inserting a plurality of electrical connectors throughthe coupler program code instructions for connecting the electricalconnectors to the power source and the atomizer. The computer readablemedium may further comprise program code instructions for coupling aheating element to a center portion of a liquid transport element toform the atomizer and program code instructions for folding first andsecond opposing arms of the liquid transport element extending from thecenter section away from the coupler. The computer readable medium mayfurther comprise program code instructions for coupling the flowdirector to a nipple of the coupler. The computer readable medium mayfurther comprise program code instructions for coupling the flowdirector to a nipple of a mouthpiece. The program code instructions forengaging the coupler with the first outer body and the second outer bodymay comprise program code instructions for engaging a rib of the couplerwith the first outer body and the second outer body.

Many modifications and other embodiments of the disclosure will come tomind to one skilled in the art to which this disclosure pertains havingthe benefit of the teachings presented in the foregoing descriptions andthe associated drawings. Therefore, it is to be understood that thedisclosure is not to be limited to the specific embodiments disclosedherein and that modifications and other embodiments are intended to beincluded within the scope of the appended claims. Although specificterms are employed herein, they are used in a generic and descriptivesense only and not for purposes of limitation.

1. An aerosol delivery device, comprising: a first outer body definingan inlet aperture; a second outer body; a power source positioned in thefirst outer body; an atomizer positioned in the second outer body; and acoupler positioned between, and engaged with, the first outer body andthe second outer body, the coupler defining a coupler inlet and alongitudinal channel, the coupler being configured to receive air fromthe inlet aperture defined in the first outer body through the couplerinlet and to direct the air through the longitudinal channel to thesecond outer body.
 2. The aerosol delivery device of claim 1, furthercomprising at least one securing mechanism configured to substantiallyirreversibly secure the first outer body to the second outer body. 3.The aerosol delivery device of claim 2, wherein the at least onesecuring mechanism comprises a wrapper extending at least partiallyaround the first outer body, the second outer body, and the coupler. 4.The aerosol delivery device of claim 1, further comprising a reservoirsubstrate and a flow director positioned in the second outer body, theflow director extending at least partially through the reservoirsubstrate.
 5. The aerosol delivery device of claim 4, wherein thecoupler defines a nipple and the flow director engages the nipple of thecoupler.
 6. The aerosol delivery device of claim 4, further comprising amouthpiece defining a nipple, wherein the flow director engages thenipple of the mouthpiece.
 7. The aerosol delivery device of claim 4,wherein the flow director defines a transverse aperture extendingtherethrough, the atomizer extending through the transverse aperture. 8.The aerosol delivery device of claim 1, further comprising a pluralityof electrical connectors extending from the atomizer through the couplerto the power source.
 9. The aerosol delivery device of claim 1, whereinthe atomizer comprises a heating element and a liquid transport elementdefining a center portion and first and second opposing arms extendingtherefrom, the heating element being coupled to the center portion ofthe liquid transport element.
 10. The aerosol delivery device of claim1, wherein the coupler defines a rib, the rib separating the first outerbody from the second outer body.
 11. A method for assembling an aerosoldelivery device, the method comprising: positioning a power source in afirst outer body defining an inlet aperture; positioning an atomizer ina second outer body; and engaging a coupler defining a coupler inlet anda longitudinal channel with the first outer body and the second outerbody such that the coupler is positioned to receive air from the inletaperture defined in the first outer body through the coupler inlet andto direct the air through the longitudinal channel to the second outerbody.
 12. The method of claim 11, further comprising substantiallyirreversibly securing the first outer body to the second outer body witha securing mechanism.
 13. The method of claim 11, wherein substantiallyirreversibly securing the first outer body to the second outer body withthe securing mechanism comprises wrapping a wrapper at least partiallyaround the first outer body, the second outer body, and the coupler. 14.The method of claim 11, further comprising positioning a reservoirsubstrate and a flow director in the second outer body such that theflow director extends at least partially through the reservoirsubstrate.
 15. The method of claim 14, wherein positioning the atomizerin the second outer body comprises inserting the atomizer through atransverse aperture extending through the flow director.
 16. The methodof claim 14, further comprising coupling the flow director to a nippleof the coupler.
 17. The method of claim 14, further comprising couplingthe flow director to a nipple of a mouthpiece.
 18. The method of claim11, further comprising inserting a plurality of electrical connectorsthrough the coupler; and connecting the electrical connectors to thepower source and the atomizer.
 19. The method of claim 11, furthercomprising coupling a heating element to a center portion of a liquidtransport element to form the atomizer; and folding first and secondopposing arms of the liquid transport element extending from the centersection away from the coupler.
 20. The method of claim 11, whereinengaging the coupler with the first outer body and the second outer bodycomprises engaging a rib of the coupler with the first outer body andthe second outer body.
 21. A coupler for an aerosol delivery device, thecoupler comprising: a first engagement portion configured to engage afirst outer body; a second engagement portion configured to engage asecond outer body; a coupler inlet defined through a peripheral surfaceof the first engagement portion; and a longitudinal channel in fluidcommunication with the coupler inlet and extending through the secondengagement portion to a coupler outlet opening.
 22. The coupler of claim21, further comprising a pressure port opening in fluid communicationwith at least one of the coupler inlet and the longitudinal channel andextending through the first engagement portion.
 23. The coupler of claim21, wherein the coupler inlet is defined between first and secondgrooves configured to respectively receive a gasket.
 24. The coupler ofclaim 21, further comprising a recessed portion at the peripheralsurface of the first engagement portion, the coupler inlet being definedthrough the recessed portion.
 25. The coupler of claim 21, furthercomprising a nipple configured to engage a flow director, thelongitudinal channel extending through the nipple.